What are the limitations of the various forming processes and the accuracy that may realistically be achieved?

The limitations of various forming processes, such as forging, rolling, and casting, primarily revolve around material properties, geometric complexity, and surface finish. For instance, processes like casting may struggle with achieving tight tolerances and intricate details, while forging can enhance strength but may limit complexity. Additionally, the accuracy achievable is often constrained by factors such as tooling precision, material flow characteristics, and thermal effects during processing. Realistically, most forming processes can achieve tolerances ranging from ±0.5% to ±5%, depending on the method and material used.